Restoring SIMATIC Field PG M3 to Factory State with Recovery DVDs

1. Overview

The SIMATIC Field PG M3 is a rugged industrial programming device designed for commissioning, programming, and diagnostics of SIMATIC S7-300/S7-400 controllers, ET 200 I/O, SINAMICS drives, and SIMOTION motion controllers. It shipped with a pre-installed Windows 7 Ultimate (32-bit) image, the STEP 7 V5.5 toolkit, an early TIA Portal version, and the Automation License Manager for floating/standalone license handling.

When the operating system becomes unstable, the recovery partition is wiped, or the hard disk is replaced, the device must be returned to its original factory state using the Siemens restore DVD set. This article documents the official recovery paths, the model identification procedure for the 6ES7715-1CC24-0BE2 configuration, and the step-by-step reinstallation of the Windows and SIMATIC software stack when the original media is not physically available.

2. Device Identification and Article Number Decoding

Before requesting any recovery media, capture the full MLFB (Siemens order number) from the rating plate on the bottom of the unit. For the configuration covered in this article the plate reads:

Record the serial number (S-Nr) and production date (FD) on the same plate. Siemens support requires both before issuing replacement media. The device type label is typically located under the service hatch near the battery compartment.

3. Recovery Strategy Selection

Three valid recovery paths exist for the Field PG M3. Choose based on the condition of the device and the availability of media.

4. Obtaining Official Recovery Media

Siemens does not publish the original restore DVD ISO images for the Field PG M3 on a public download portal. The legal and supported path to obtain replacement media is through Siemens spare-parts ordering.

4.1. Required Information for the Order

1. Full MLFB: 6ES7715-1CC24-0BE2
2. Serial number (S-Nr) from the rating plate
3. Production date / FD code (e.g. FD 12.2014)
4. Delivery address and Siemens customer number (if available)

4.2. Siemens Order Channels

Open a support request through the Siemens Industry Online Support portal at support.industry.siemens.com. The article Tool-Downloads for SIMATIC IPCs, SIMATIC Tablet PCs and SIMATIC Field PGs lists the available ISO/IMG bundles per IPC family and indicates which of them can be downloaded directly versus which require a spare-parts order.

For the Field PG M3, the relevant spare-part article number is the SIMATIC Field PG M3 recovery DVD set, which is ordered via the Siemens spare-parts service. The lead time is typically 5-10 business days for EU customers and longer for non-EU regions. Provide the MLFB so the correct region-specific image (German, US, Chinese, etc.) is supplied.

5. Pre-Restore Hardware Checks

Before booting from the restore DVD or USB, verify the following to avoid restore failures:

1. BIOS version: Enter BIOS (F2 at POST) and record the version. The M3 shipped with BIOS revisions from AMI. If a BIOS update has been applied, confirm the recovery image matches the current BIOS; otherwise re-flash the BIOS to the factory version using a DOS-bootable USB.
2. Hard disk health: Boot to the BIOS hardware diagnostic (F12 → Diagnostics) and run the SMART short and extended tests. Replace the HDD/SSD if reallocated sectors exceed threshold.
3. Battery: Verify the CMOS/RTC battery (CR2032) holds ≥ 2.8 V. A flat battery resets BIOS settings during the restore and can cause the restore to abort.
4. AC adapter: Connect the supplied 90 W Siemens PSU (article 6ES7798-0AA03-0XA0 or the regional equivalent). A generic 19 V adapter without the proper center-pin identification may be rejected by the charge controller.
5. Boot order: Set boot order to USB-DVD → USB-HDD → SATA0.

6. Restore Procedure Using the Original DVD Set

1. Power on the device and press F12 at POST to open the boot menu.
2. Insert DVD 1 of the restore set into the optical drive. Select PIONEER DVD-RW DVRTD11 (or the installed optical drive) from the boot menu.
3. The Siemens Restore Wizard boots into a Windows PE environment. Accept the license agreement.
4. Select Restore to factory state. The wizard offers two options:
   • Restore complete system — erases all partitions and recreates the OEM layout (recovery + Windows + data).
   • Restore Windows only — preserves the recovery partition but reinstalls the C: partition.
5. Confirm the target disk. The wizard displays the model and size of the destination disk; verify it matches the original (typically a 320 GB SATA HDD on M3, or 256/512 GB SSD on later M3 units).
6. Confirm and start. The restore takes approximately 30-40 minutes. The wizard reboots automatically when the Windows partition restore is complete.
7. Insert DVD 2 and DVD 3 when prompted for the Siemens application stack (STEP 7, TIA Portal, WinCC flexible, S7-PCT, S7-Technology, etc.).
8. After the final DVD, the system boots into the OOBE (Out-of-Box Experience). Complete the Windows 7 setup (user name, password, locale, time zone, product key from the COA sticker on the chassis).

7. Clean-Install Procedure (Path C)

If original media is unobtainable and the spare-part order is not viable, perform a clean Windows 7 install followed by manual deployment of the Siemens stack. This is the most time-consuming but most controllable path.

7.1. Windows 7 Ultimate 32-bit Installation

1. Create a Windows 7 USB installer using the official Microsoft media creation tool or by mounting the ISO via Rufus. Use a 4 GB or larger USB stick, set partition scheme to MBR and target system to BIOS (the M3 has a traditional BIOS, not UEFI).
2. Boot the device from the USB and run the Windows setup. Delete all existing partitions on the target disk before selecting the unallocated space.
3. During setup, decline the prompt to enter a product key; instead use the key from the COA sticker after the first boot, or skip and run activation later.
4. Disable Windows Update automatic reboots and disable the hibernation file to reduce disk wear on the installed SSD.

7.2. Required Driver Set

The M3 requires the following driver package. Source them from the same Siemens download area mentioned in section 4 or from the recovery image you may have obtained from a peer.

8. Siemens Software Stack Deployment

After Windows and drivers are in place, deploy the SIMATIC application stack. The versions below match the original M3 factory image; later versions are compatible in most cases.

8.1. STEP 7 V5.5 (Mandatory for S7-300/400)

1. Insert the STEP 7 V5.5 DVD (article 6ES7810-4CC10-0YA5 for the latest V5.5 SP bundle).
2. Run Setup.exe from the root. Accept the license agreement.
3. Select Installation: STEP 7 V5.5 + S7-PCT + S7-Technology + S7-GRAPH (the standard install for M3).
4. During installation, choose CP 5611 / CP 5621 as the PG/PC interface module. Set the PG/PC interface to PC internal (local) or CP 5611 (PROFIBUS) depending on your network.
5. Reboot and run SIMATIC Manager to verify the S7-300/400 station can be created.

8.2. TIA Portal (V13-V16 supported on M3)

1. Insert the TIA Portal DVD or mount the ISO. The latest version compatible with the M3 hardware is V16, but the factory image typically shipped V13 SP1.
2. Run the Start executable. The setup guides you through STEP 7 Professional, WinCC Professional, and Safety options.
3. Select Install TIA Portal with all options to obtain a complete engineering environment for S7-1200/1500 and S7-300/400.
4. After the main install, launch the Automation License Manager to migrate any existing license keys from a backup or another PG.

8.3. SIMATIC NET PC Software

Required for PROFINET IO controller / IO supervisor diagnostics and for S7 routing. Install the SIMATIC NET PC Software V14 SP1 DVD or download the equivalent. The CP 1616 board is added as a Windows network adapter with the Siemens PROFINET IO protocol stack layered on top.

8.4. Optional Tools

9. License Restoration with Automation License Manager

Licenses for the SIMATIC software are stored in license keys on the local C: drive (standalone) or on a network license server. After a fresh install, the license keys are gone and must be re-activated.

9.1. License Key Recovery Procedure

1. Locate the original Certificate of License (CoL) documents or the License Key USB stick (red USB) shipped with the device.
2. Open Automation License Manager (Start → Siemens Automation → Automation License Manager).
3. From the menu, select License Key → Reinstall if you still have a backed-up .aks file, or Activate Trial License to run for 14 days while you re-activate from the Siemens license server.
4. For online activation, log in with your Siemens Single Sign-On account and download the licenses to the local C: drive. The license is bound to the host ID (a hash of the C: drive serial number + system UUID).

9.2. Backing Up Existing Licenses Before Restore

If the device still boots and you intend to wipe the disk, perform the following BEFORE starting the restore:

1. Start Automation License Manager.
2. Right-click each license → Backup... and save to a USB stick.
3. Also export the host ID via License Key → Host ID to a text file on the same USB.

This precaution is critical for sites with multiple license keys and no central license server.

10. Verification and Commissioning

After the restore and software deployment, run the following verification sequence before returning the device to production.

10.1. Hardware Verification

1. Open Device Manager and confirm no unknown devices are listed. Any yellow exclamation indicates a missing driver.
2. Open the Siemens PG/PC interface tool and confirm the CP 5611 (PROFIBUS) or CP 1616 (PROFINET) entry is present and bound to the SIMATIC NET protocol.
3. Run Siemens Field PG Diagnostics from the Start menu (Siemens Automation → Tools). The tool exercises the LCD, keyboard, battery, and the diagnostic LEDs.
4. Check the battery calibration by running the BIOS → Power Management battery recalibration cycle (typically 6-8 hours for a full cycle).

10.2. Software Verification

1. Open SIMATIC Manager and create a new S7-300 station. Compile and download a small test program to a real S7-300 CPU on the MPI bus to confirm online communication.
2. Open TIA Portal and create a new S7-1500 project. Run Online → Accessible nodes to confirm the PG sees the PROFINET network.
3. Open Automation License Manager and confirm all expected license keys are displayed as valid (green check).
4. Open a Windows command prompt and run winver to confirm Windows 7 Ultimate 32-bit SP1 is the active build.

10.3. Acceptance Checklist

11. Troubleshooting Matrix

12. Preventive Maintenance Recommendations

1. Create a recovery USB after every successful restore. Boot to the Siemens Image & Restore Creator (bundled on the recovery DVD or available from the Siemens support area) and store the image on an external USB HDD labelled with the MLFB and date.
2. Back up license keys and the host ID to a USB stick in a safe location, away from the PG.
3. Disable Windows hibernation (powercfg -h off) to reduce SSD wear.
4. Disable Windows Update automatic reboots via Group Policy (gpedit.msc → Computer Configuration → Administrative Templates → Windows Components → Windows Update → "No auto-restart with logged-on users").
5. Replace the CMOS battery every 3 years as a preventive measure.
6. Document the installed versions in the device's logbook. The field service tech who restores the device two years later will thank you.

13. References to Official Siemens Documentation

The following Siemens Industry Online Support articles and TIA Portal documentation are the primary sources for the procedures in this article:

• Tool-Downloads for SIMATIC IPCs, SIMATIC Tablet PCs and SIMATIC Field PGs — Siemens Industry Online Support entry listing the available tool downloads and ISO images for the SIMATIC programming-device and IPC families.
• Siemens Industry Online Support — central portal for manuals, firmware, FAQs, and spare-parts requests for all SIMATIC products.
• S7-1200 CPU backup and restore options (TIA Portal cloud documentation) — covers the complementary backup/restore flow on the S7-1200 CPU side, useful when a Field PG is used to push a configuration to a fresh CPU.